Main Drive Gear and Mainshaft Assembly

Main Drive Gear and Mainshaft Assembly

Component Identification: Main Drive Gear and Mainshaft






Apply transmission lubricant to all parts as they are assembled

Combine Step 1 thru 5
1. Get the Main Drive Gear







2. Install the Main Drive Gear Bearing
- Place the Main Drive Gear onto SST 49- B019-007
- Use a press and SST 49-0500-330 and SST 49-B019-007 to drive the bearing on













3. Get the 5th/ Main Drive Gear Selective Snap-Ring
- Install the Snap-Ring removed during disassembly into its groove
- Measure the clearance between the snap ring and the groove
- Add the feeler gauge thickness to the Snap-Ring thickness
- Use the chart to select the correct Snap-Ring so that the clearance is standard
- Replace the Snap-Ring with a new one even if it is the correct size
- Remove the old Snap-Ring and replace it with the new Snap-Ring




4. Place the 5th Synchronizer Ring onto the Main Drive Gear




5. Insert the 5th Needle Bearing into the Main Drive Gear

Combine Step 6 thru 10 for the 5th/ Reverse Clutch Hub




6. Get the 5th/Reverse Clutch Hub
7. Insert the 3-Synchronizer Keys into the clutch hub
8. Insert the 3-Synchronizer Key Springs into the synchronizer keys
9. Insert the 3-Steel Balls into the springs
- Hold 2-balls in position with the thumb and index finger of one hand and hold the 3rd ball in position with your other index finger




10. Use the picture to align the clutch hub and sleeve so they are facing the correct direction




- Align the notches in the sleeve with the keys in the hub




- Press the balls to compress the springs
- Slide the sleeve over the hub

Combine Step 6 thru 10 for the 1st/2nd Clutch Hub




6. Get the 1st/2nd Clutch Hub
7. Insert the 3-Synchronizer Keys into the hub
8. Insert the 3-Synchronizer Key Springs into the keys
9. Insert the 3-Steel Balls into the springs
- Hold 2-balls in position with the thumb and index finger of one hand and hold the 3rd ball in position with your other index finger







10. Use the picture to align the clutch hub and sleeve so they are facing the correct direction
- Align the keys in the hub with the notches in the sleeve
- Press the balls to compress the springs
- Now slide the sleeve over the hub




11. Get the Mainshaft




12. Place the reverse Needle Bearing onto the Mainshaft




13. Place Reverse Gear onto the Needle Bearing




14. Place the reverse Synchronizer Ring onto the reverse gear cone










15. Place the 5th / Reverse Clutch Hub onto the Mainshaft
- Use the picture and make sure the hub is facing the correct direction
- Align the tabs on the synchronizer ring with the grooves in the hub
- Make sure the synchronizer ring tabs stay aligned with the grooves in the hub, when pressing the clutch hub onto the shaft
- Press the 5th / Reverse Hub onto the mainshaft using SST 49-N017-104 and SST 49-N017-102













16. Selective Snap-Ring (Reverse Gear)
- Install the correct snap ring removed during disassembly into its groove
- Measure the clearance between the snap-ring and the groove
- Add the feeler gauge thickness to the Snap-Ring Thickness
- Use the chart to select the correct snap-ring so that the clearance is standard
- Replace the Snap-Ring with a new one even if the old Snap-Ring is the correct size
- Remove the old Snap-Ring and replace it with the new Snap-Ring




17. Install the 2nd gear Needle Bearing




18. Install 2nd Gear

Combine Step 19 thru 22





19. Install the Inner Ring
- See the illustration to align the ring

20. Install the Middle Ring
- See the illustration to align the ring




21. Install the Synchronizer Ring
- See the illustration to align the ring













22. Install the 1st /2nd clutch hub to the mainshaft
- Be very careful and very patient while pressing the hub on. It is easy to misalign the triple synchronizer rings or have a mishap that causes the sleeve to come off and springs and keys will fly everywhere
- Place the 1st /2nd Hub onto the Mainshaft
- Get SST 49-N017-103, SST 49- N017-104, and SST 49-N017-102
- Align the tab of each synchronizer ring with the notches in the hub
- See the illustration to align the rings
- Keep the pieces aligned when pressing the parts together

Combine Step 23 thru 26




23. Install the Steel Index Ball for the inner race {part #29} into the Mainshaft







24. Place the Synchronizer Rings onto the Mainshaft
25. Middle Ring
26. Inner Ring




27. Install 1st Gear onto the Mainshaft







28. Install the 1st gear Needle Bearing
29. Install the 1st gear Inner Race
- After Step 23 to 29 align all of the pieces




30. Place the rear Bearing onto the mainshaft










31. Install 6th Gear onto the mainshaft
- Get SST 49-N017-103 and SST49-N017-102
- Press on 6th Gear and the Bearing










32. Get the Selective Snap-Ring (Mainshaft 6th gear)
- Install the correct Snap-Ring removed during disassembly into its groove
- Measure the clearance between the snap-ring and the groove
- Add the feeler gauge thickness to the Snap-Ring thickness
- Use the chart to select the correct Snap-Ring so the clearance is standard
- Replace the snap ring with a new one even if the old Snap-Ring is the correct size
- Remove the old Snap-Ring and replace it with the new Snap-Ring




33. Place the Main Drive Gear onto the Mainshaft




Assembled Mainshaft